Electrochemical Cell Assembly With Pivoting Flaps for Faster Tab Welding
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Solution Overview
Problem
Current electrochemical cell manufacturing processes are complex and time-consuming due to the difficulty in applying laser beam welding to copper negative electrode bundled tabs and ultrasonic welding to aluminum positive electrode bundled tabs, resulting in poor welding quality and prolonged process times.
Innovation Solution
A manufacturing process involving a single-step laser welding of connection elements positioned on the side faces of electrode assemblies, using supporting tools with pivoting flaps to facilitate welding of both copper and aluminum collectors, eliminating the need for ultrasonic welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If laser beam welding is applied to copper negative electrode bundled tabs, then welding speed is improved, but welding quality deteriorates due to high reflectivity
Solution Approach 1:
The patent applies parameter changes by modifying the laser beam parameters (wavelength, power, pulse duration) and welding parameters (speed, focal position) to optimize the welding process for copper materials with high reflectivity, thereby achieving both high welding speed and high welding quality
2Manufacturing precision
If ultrasonic welding is applied to aluminum positive electrode bundled tabs, then welding quality is improved, but process time increases
Solution Approach 1:
The patent replaces the mechanical ultrasonic welding system with a laser beam welding system, substituting mechanical vibration-based welding with optical/thermal-based welding, thereby reducing process time while maintaining welding quality through optimized laser parameters
3Manufacturing precision
If multiple welding methods are used for different electrode connections, then welding quality is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by using a single laser beam welding system that can weld both copper and aluminum materials by adjusting laser parameters, replacing the need for separate ultrasonic welding equipment and multiple welding methods, thereby simplifying the overall welding system while maintaining welding quality for different materials
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies and accelerates the manufacturing process by enabling quick and high-quality welding of both copper and aluminum connections, reducing process time and improving overall efficiency.
Implementation Method 1
a step of welding the first connection elements to the first collector, a second step of welding the second connection elements to the second collector
Data Source
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AI summary
The invention relates to a process for manufacturing an electrochemical cell comprising in particular: - a step for providing two electrode assemblies (2, 3), - a step of translating two supporting tools (36, 37) toward the electrode assemblies to insert each electrode assembly into one of the supporting tools, - a step of pivoting two first pivoting flaps (54', 55') of the supporting tools, up to abutment against first tabs (30, 31), - a step of pivoting two second pivoting flaps (54, 55) of the supporting tools, up to abutment against second tabs (32, 33), - a first step of welding the first connection elements (4, 5) to the first collector, - a second step of welding the second connection elements to the second collector.